Roofing



July 1l, 1939. P. LOGAN 2,165,865

ROFING l Filed May 16, 1956 2 Sheets-Sheet 1 lrzf/'en'ar Paul L @an Pareted July 1-1,A 1939 UNITED STATES `PATENT oFFicE Paul Logan, Chicago, Ill., assignor to The Logan- Iilijllig Company, Chicago, Ill., a corporation of Application May 16, 1936,` Serial No. 80,091 4 Claims. (Cl. 108-8) My inventionI relates to roofing, and includes among its objects and advantages a material reduction in the cost of roong of the type built up chieily of felt and asphalt with or without a gritl surfacing; the utilization of waste material accumulating in the manufacture of such roofimg; an expedient for preventing applicators from economizing too much on overlap; and the production of new designs. Further objects and advantages of the invention will become apparent as the description proceeds.

The type of roofing common in the art and commonly referred to as flexible asphalt roofing has, in the past, practically always been built up of a strip of felt impregnated with asphaltum, and then surfaced with a coat or layer of additional asphaltum, and then usually surfaced a second time with small pieces of slate or equivalent materials commonly referred to as grits. After the production of a continuous strip of such material the strip has to be cut into smaller pieces. Even when these pieces are smaller strips of considerable length, commonly referred to as roll roofing, there is material waste in cutting up the continuous strip, and the scraps accumulate. In many instances such a continuous strip is cutinto individual shingles or strip shingles,

and in such cases there is usually a materially greater amount of small pieces that are of no use at all in the form in which they accumulate. In roofing such as has just been described, the most expensive element or portion is the felt. According to my invention it is possible, not only to utilize the clippings or waste accumulated in producing roofing according to the prior art, but roong according to the present invention can be built up entirely from new raw materials utilizing no fibrous ingredients at allor materially cheaper forms of fibrous ingredient than the felt required for roofing according to the prior art. g v

In the accompanying drawings: l Figure 1 is a diagram indicating the steps in one process of producing roong according to the invention;

Figure 2 is a sectional view as on line 2-2 Figure 1; f Figure 3 is: an end elevation of the forming die as on line 3 3 of Figure 1;

. Figure 4 is ya section of two` overlapping shingies in such a position as they would occupy on a roof;

Figures 5,.6, 7, and 8 are slmilarcross sec- I tions illustrating variations in shingle shapes;

Figure 9 isa diagram of one way of laying shingles according to Figure 8; and t Figure 10 is a diagram of one way of laying shingles according to Figure 7.

In the embodiment of the'invention indicated 5' in Figure 1, I0 is a rotary kiln havngany suitable drive means indicated at I2, and heating means indicated as a burner at Il. Into this kiln the ingredients for the mix arecharged. Scrap from the manufacture of ordinary roofing, l0 including such grits as may be sticking to the scrap, forms a satisfactory charge in nearly every instance, but may, if desired, be supplemented by additional materials to secure any desired proportion of ingredients that may happen to differ slightly from the composition of the scrap. In using other raw materials the kiln may be charged with asphaltum, plastic wood, or equivalent mastic materials, which may be supplemented by fillers such as powdered clay, dolomite or the like, or by iibrous illler or by both. The brous illlers may include asbestos fibre, but for most grades I can use the type of fibre from which ordinary roofing felt is made. 'I'his eliminates the expense of making the fibre up into felt. It is also possible to use cheaper grades of libre with entirely satisfactory results.

The charge' in the kiln is heated until it becomes a plastic or viscous mass, but it is not valways convenient to operate the kiln so that a satisfactorily complete mixing takes place in the kiln. IB indicates a mixer into which heated material from the kiln is charged. I have indicated a discharge spout, I8 for continuous charging to enhance the cleamess of the drawings. In the mixer I6 the plastic or viscous mass is agitated as by paddles 20 enough to produce a satisfactory degree of homogeneity or Lmiformity in the mix. The mixed material is then transferred to an extrusion device for forming a continuous strip therefrom. I have indicated a continuous discharge from the mixer by means of the spout 22, and an extrusion device including the housing 24, the worm 26, and the die 28. 'Ihe die 28 is shaped to deliver a strip having the com- 45 plete cross section of a finished shingle, and with ingredients such as I have described, it is possible to produce such shingles having superior strength characteristics without any underlying felt support at all. The s'trip leaving the die 28 is substantially solid. When it is to be used with a grit surfacing, I reheat the entire strip, or at least the portion destined to receive the grits. I have indicated guiding rolls 30 for conveying the strip to a re- 55 heat kiln 32. The kiln illustrated comprises a housing 34 4ol! refractory material having the shape of an inverted U, and overlying the strip 38. In the illustrative embodiment of Figure 2, the top and right hand walls of the kiln are strongly heated as by a flame 38 issuing `from a burner 48. Particularlywhen the strip 36 has irregularities in its upper surface, I may preserve the shape of such irregularities by positioning the strip as clearly indicated in Figure 2 so that the portion of the upper surface having the irregularity is not directly exposed to the radiant heat in the kiln but substantially shielded therefrom by the lower edge of the left hand wall of the kiln. In this way the heating action may be localized over that portion of the surface to which the grits are to be applied, and that portion of the surface may be heated to incipient fusion or to build up a very thin surface layer of entirely molten material.

Immediately upon issuing from the kiln 32 the strip receives suitable grits 42 from a hopper 44, and then passes through rollers 46 which press the grits into the asphalt, and cutting rolls 48 which cut the strip transversely. It will be obvious that these rolls may notch the edge of the strip and make complete transverse cuts between the notches so as to form the well known form of strip shingles, or that all the transverse cuts may sever the strip completely, thereby forming individual shingle pieces. Any of the designs known to the prior art can be produced with equal facility by the rolls ,48.

The forming process just described facilitates the` formation without any waste whatever of any desired predetermined cross section. Referring to Figure 4 I have illustrated shingles 50 ,of substantially plain rectangular cross section except for a slight taper in the upper half of the shingle. It will be noted that when such shingles 50 are laid, there will be spaces' between the shingle and the supporting roof boards, as indicated at 52 in' Figure 4. Figure 5 indicates a shape that can be produced with equal facility. The exposed surface in Figure 5 is identical with that in Figure 4, but the space 52 has been fllled in solid by merely changing the shape of the die so that the lower surface of the shingle has a shoulder at 54 having a height equal to the height of the upper edge of the underlying shingle.

In Figure 6 I have indicated a shingle shaped with a downwardly facing shoulder at 56 formed on the upper face of the underlying shingle near its upper edge. The lower edge of the overlying shingle is formed with a complementary shapev so that the assembled shingles not only interlock but fit together without any air spaces or pockets anywhere. Y

The shape of the shingles of Figure 7 differs fromthat in Figure 6 in that all the shoulders are inclined downwardly at a suitable angle, which I have indicated as 45. Thus the shoulder 58 has a decided hook shape which renders the interlock somewhat more effective.

In Figure 8 I have indicated the ease with which shingles with the same type of interlock as in Figure '7 can be designed to lay a roof of two or more thicknesses by merely moving the shoulders 'I8 to the position illustrated and shaping the under surface of the overlying shingle to correspond. I have also indicated the exposed lower edges of the shingles beveled as at 80 at such an angle that they can receive and retain grits. A finished roof of shingles according to Figure 8, accordingly, will present to the eye a continuous surface of grits, without the sharp discontinuities formed by the lower edges of shingles according to Figure 7.

The conditions attending manufacture of roofing according to the prior art have been such that users have become accustomed to regarding a heavy shadow line as indicating a superior product. It will be noted that the lower edges of any of the shingles of Figures 4 to 8 may be made of any desired thickness, and may terminate at any desired angle, and may be surfaced with grits or left uncovered and additionally conspicuous by reason of the dark color of the mastic. In Figure 9 I have shown a plan view of a portion of a roof employing shingles according to Figure 8. It will be noted that the shingle 82 extends up behind the lower edges of the second course of shingles f above. Such a roof is complete in itself and can be laid over new roof boards or over old roofing.

Shingles according to Figure rI can also be l-aid in the same way, but only over roll roong or some other means for stopping the cracks between adjacent shingles in the same course. However, a Dutch lap roof complete in itself can advantageously `be laid with shingles according to Figure 7. In Figure 10, the shingle 84 has its hook-shaped portion 58 located as indicated, and its right edge terminates at 60. A single fastening only is shown at 86. The dotted line at 88 indicates the lower edge of the next course of shingles, which can* be laid with their vertical joints in any desired relationship to the joints in the course below. 'I'he nails applied to fasten down the lower edge of each course will also penetrate the upper edge of the course below.

Without further elaboration, the foregoing will so fully explain my invention that others may, by applying knowledge current at the time of application, readily adapt the same for use under various conditions of service. It will be apparent that any material which can be called mastic, in the sense that it is capable of changing from a state or condition capable of being rolled or shaped 'by plastic deformation, into a condition of greater strength or rigidity, as by cooling or by chemical action, can be processed according to the present invention.

I claim:

1. A roof comprising, in combination: a supporting roof structure; overlapped shingles on said structure; each shingle being composed of a body of mastic material; an upper edge portion of each shingle underlying a lower portion of an adjacent second shingle higher up and extending under said second shingle to a point below a lower edge portion of a third shingle still higher up; said first mentioned shingle having an upper surface sloping gently toward the plane of said supporting roof structure; said sloping surface having a single downwardly facing shoulder approximately-midway between the upper edge of said first shingle and the lower edge of said second shingle; the under surface of said second shingle having an upwardly facing shoulder fitting into said downwardly facing shoulder; said shoulders being hook-shaped, whereby the second shingle is held down by inter-engagement of said shoulders; the upper edge of said first mentioned shingle being beveled with its sharper edge next the bottom; said second shingle having its under surface shouldered to lit said edge; all said shingles being of identical cross section and tting together without distortion of the mastic material into a substantially solid mass without air pockets; the lower edges of said shingles being adsense i beveled with their sharper edges nent the bottom; the exposed surface portion and the beveled lower edge ol each shingle being substantially covered with weather-resistant granular material embedded in the mastic material; said shingles being of uniform cross section irorn side to side.

2. d rooi comprising, in combination: a supporting root" structure; overlapped shingles on said structure; each shingle being composed of a body ol mastic material; an upper edge portion oi' one shingle underlying a lower portion oi an adjacent second shingle higher up; the upper suriaoe oi said first mentioned' shingle having a downwardly facing shoulder; the under surface oi said second shingle having an upwardly iacing shoulder litting into said downwardly facing shoulder; said shoulders being hook-shaped, whereby the second shingle ls held down by in tereengagernent oi said shoulders.

3. d root comprising, in combination: a supnorting root structure; overlapped shingles on said structure; each shingle being composed of a body of mastic material; an upper edge portion of each shingle underlying a lower portion of'an adjacent second shingle higher up; said first mentioned shingle having an upper surface sloping gently toward the plane of the supporting roof structure; said sloping surface having a single downwardly facing shoulder approximately inidway between the upper edge oi sai-d nrst shingle and the lower edge of said second shingle; the under surface of said second shingle having an upwardly lacing shoulder iltting into said downwardly lacing shoulder; said shoulders being' hook-shaped, whereby the second shingle is held down by inten-engagement ci said shoulders; said second shingle having its underI surface shouldered to nt the upper edge oi said hrst mentioned shingle; all said shingles being ot identical cross section and ntting together without distortion or the mastic material into a substantially solid mass without air pochets.

d. A roof comprising, in combination: a supporting roof structure; overlapped shingles on said structure; each shingle being composed of a body of mastic material; an upper edge portion of each shingle underlying a lot/ver portion of an adjacent second shingle higher up; said hrst mentioned shingle having a single downwardly lacing shoulder approiiiniately midway between the upper edge oi said first shingle and the lower edge or' said second shingle; the under surface of said second shingle having an upwardly lacing shoulder dtting into said downwardly 'facing shoulder; said shoulders being hook-shaped, whereby the second shingle is held down by interengagernent or said shoulders; the upper edge of said first mentioned shingle being beveled with its sharper edge next the bottom; said second shingle having its under surface shouldered to fit said edge; said edge engagement and the engagement of said hook-shaped shoulders being on laces lying in substantially parallel planes.

PAUL LUGdN. 

